Woven combined fabric body and pad and method of weaving



June 13, 1950 H. P. FARIS El AL 2,511,500

WOVEN COMBINED FABRIC BODY AND PAD AND METHOD OF WEAVING Filed Feb. 9, 1949 5 Sheets-Sheet 1 GROUP 25 I F/ a. 4. 25

IN VEN TOR.

HAROLD P. FAR/S & BERNARD R. KOEN/G ATTORNEYS June 13, 1950 H. P. FARIS ET AL 2,511,500

WOVEN COMBINED FABRIC BODY AND PAD AND METHOD OF WEAVING Filed Feb. 9, 1949 3 Sheets-Sheet.2

GROUP @QQ gQQ GROU 22% 02a 22 02s INVENTOR. HAROLD P. FAR/S '& BERNARD R. KOE/V/G ATIORNEYS' June 13, 1950 H. P. FARIS Er- AL I 2,511,500 WOVEN COMBINED FABRIC BODY AND PAD AND METHOD OFWEAVING Filed Feb. 9, 1949 s Sheets-Sheet 3 u-nllm nu- 1 'IIIIIIII 'wzum s 1.5 26 1 32 FIG. /4. 7 21 s 29 30 2 INVENTOR. 1 HAROLD P. FAR/5 8 10 BgRNARD R. KOEN/G 11 Y d F [6. l7. ATTQRNEYS Patented June 13, 1950 WOVEN COMBINED FABRIC BODY PAD AND METHOD OF WEAVING Harold P. Faris, Sellersville, and Bernard R.

Koenig, Westgate Hills, Pa., assignors to Prodesco, Inc., Perkasie, Pa., a corporation of Pennsylvania Application February 9, 1949, Serial No. 75,314 Claims. (Cl. 139--384) This invention relates to an improvement in pads for carpets or other woven fabrics which may be woven separately from the fabric or as a composite part therewith, in which the body portion of the fabric is formed of the body of the pad and the method of weaving the pad or the pad together with the overlying or decorative face of a fabric combined with a pad.

One of the objects of our invention is the provision of a pad having a substantially closed upper surface formed of the body forming warp and weft threads, and, when woven as a composite part of a fabric or carpet, the decorative portion of the fabric overlies the upper surface of the pad formed of warp threads interwoven with body forming weft threads, the. only threads added to the pad forming threads for weaving a carpet or other fabric combined with a pad.

Another object of our invention is the provision of a pad and method of making the same in which a substantially closed upper surface is formed by the upper portion of, or body portion of, the pad, while the lower portion or base is of open or honeycomb weave with body supporting pillars between the top or body portion and the base.

Another object of our invention is the provision of .a fabric provided with an under pad without appreciably increasing the weight of the material required for a composite fabric and especially for a carpet with an integral pad.

Another object of our invention is the provision of a fabric or carpet combined with an underlying pad, in which the weft and warp threads of the upper portion or base of the pad. forms the base or body of the carpet, the face of the carpet being formed entirely of face forming warp threads interwoven with the weft threads in the top or body portion of the pad. Having now described in a general way the nature and purpose of our invention, we will proceed for illustrative purposes to a detailed description of a preferred embodiment thereof with reference to the accompanying drawings, in which:

Figure l is a side elevation of one of the warp threads shown in relation to the weft threads shown in section of a pad independent of the design forming portion or face of the fabric;

Figures 2-12, inclusive, are similar views showing the remaining eleven warp threads in succession in a repeat of 12 weft threads;

Figure 13 is a, bottom plan of a pad in accordance with our invention;

Figure 14 is a plan view thereof;

Figure 15 is a longitudinal sectional view on the line it -i5 of Figure 14;

Figure 16 is a transverse sectional view on the line 16-46 of Figure 14; and

Figure 17 is a sectional view of a portion of I Figure 14 showing a portion of the pile facing of a carpet.

In Figures 13-16, inclusive, we have illustrated a pad woven of a repeat of twelve warp threads and a repeat of twelve weft threads in the particular form shown which may vary in accordance with a particular fabric backed with a pad or a pad formed without a facing such as used under a carpet or rug.

The warp threads extend in four different groups designated A, B, C and D in Figures 1-12 of three strands or ends each, alternate groups being drawn from separate beams or sources. The warps B and D are preferably formed of paper, jute or other yarn having a low friction surface and are always maintained under a high tension. The other groups A and C of strands or ends, alternating with the first group, are preferably formed of finer gauge and are drawn from a second beam or source under light tension when compared to the tension under which the first mentioned groups are maintained in order to permit the withdrawal of warp from the second source when no warp is being drawn from the other source.

When the pad is interwoven with the decorative portion or the face of the carpet, the warp threads, therefore, are drawn from a third source or beam, i. e., the usual source from which such threads are drawn when weaving carpet or other fabric.

In the drawings, the warp threads or strands of each repeat are designated by the reference characters I, 2, 3, i, 5, 6, l, 8, 9, iii, H and [2 which are divided into four groups, i. e., group A, comprising strands i, 2 and 3; group B, comprising strands 3, 5 and 6; group C, comprising strands l, 8 and 9 and group D, comprising strands H], if and H2.

The strands or warp threads of groups B and D are preferably of jute of low surface friction and are drawn from the same source under high tension, while the warp threads of groups A and C are drawn from the second source and are preferably of lighter gauge and under low tension permitting weft threads being interwoven with warp threads, while warp threads in groups B and D are held stationary by high tension.

The weft threads are designated by the reference characters 2|, 22, 23, 2d, 25, 26, 21, 28, 29, 38, 3! and 32, and, in the form shown, are all of the same gauge and are received from the same shuttle in each shed.

The pad comprises a body having a closely interwoven face of warp and weft threads, a supporting base of honeycomb formation of interwoven warp threads and weft threads and body supporting pillars between the base and body of interwoven weft and warp threads.

The body is formed of interwoven weft threads 2|, 29, 39, 3| and 32 and high tension warp threads 4, 5 and 6 of group B. The base is formed of interwoven weft threads 24, 25 and 26 and high tension warp threads I9, II and I2 of group D. The pillars are formed of weft threads 22, 23, 21 and 28 interlaced with low tension warp threads 2 and 8 of groups A and C, which threads float between pillars. The weft threads 22 and 28 of the pillars and the weft threads 2| and 29 of the body are interwoven with the low tension warp threads 3 and of groups A and C, which warp threads are interlaced with weft threads 39, 3| and 32 of the body between body weft threads 29 and 2 I, while the weft threads 23 and 21 of the pillars and the weft threads 24, 25 and 26 of the base are interwoven with the low tension warp threads I and 9 of groups A and C and float between pillars.

The high tension warp threads 4, 5 and 6 in group B extend longitudinally and in a continuous manner in the body and are interwoven with each weft thread 2|, 29, 30, 3| and 32 while the high tension warp threads I0, II and I2 in group D also extend longitudinally in a continuous manner in the base and are interwoven with weft threads 24, 25 and 26 in the base below the supporting pillars and float from pillar to pillar.

Assuming that the pad alone is woven without any warp threads to form the design of the fabric, but merely the warp and weft to form the body of the pad, the base and the interposed pillars are woven as shown in Figures 13, 14 and 15 and are moved from left to right by the loom take-up, not shown.

As shown in Figures 13, 14 and 15, the fabric is moved from right to left after each pick during the weaving of the body from weft 29 to weft 2| of the body and is substantially stationary during the weaving of the pillars.

The weft threads, 2|, 22, 23, 24, 25, 26, 21, 28, 29, 30, 3| and 32 of each repeat, beginning with weft 2|, the ending of one span of the body over one side of a pillar including the wefts in the pillar and the span including weft 32 adjacent to the weft 2! over the beginning of the pillar in the next repeat are successively numbered from 2| to 32. The order of the warp threads in each repeat as shown in Figures 14, 15 and 16 is as follows. Warp threads I, 2 and 3 of group A, 4, 5 and 6 of group B (group C is not shown in Figure 15 as these threads I, 8 and 9 are in back of group B, are the same as threads I, 2 and 3 but are positioned in the reverse order) and warp threads I9, II and I2 of group D, following group C.

All of the weft threads, as well as warp threads 4, 5 and 6 of group B and warp threads ID, I and I2 of group D have been greatly exaggerated and spaced apart for illustrative purposes as the spaces between warp threads in the body of the pad, as woven. are substantially closed.

The weft threads 2| and 29 of the body, which rests on the upper weft threads 22 and 28 of the pillars, as well as weft threads 30, 3| and 32 between weft thread 29 and weft thread 2| lie close to each other in the body to form together with the warp threads interwoven therewith a substantially smooth upper surface on the body of the pad or upper surface of the body of a carpet or other fabric if woven as a composite part of the woven article.

As before described, the warp threads 3 of group A, I of group C and 4, 5 and 6 of group B are all interwoven with weft threads 2|, 29, 30, 3| and 32, while the warp threads I of group A,

9 of group C, and I 6, II and I2 of group D are interwoven with weft threads 24, 25 and 26 to form the base of the pillars and float between pillars. Warp threads 2 and 8 of groups A and C are interwoven with weft threads 22, 23, 2'! and 28 in the pillars, which, as hereinbefore stated, are between weft threads 2| and 29 in the body of the pad and weft threads 24, 25 and 26 in the base of the pillars.

As previously stated, warp threads 4, 5 and 6 of group B and I0, I I and I2 of group D have low friction surfaces and are maintained under high tension during the entire weaving operation, while warp threads I, 2 and 3 of group A, I, 8 and 9 of group C are under a low tension and have a higher friction surface than groups B and D. By such an arrangement, if the take-up mechanism of the loom, not shown, is arrested during the weaving, the high friction applied to warp threads of groups B and D are held substantially stationary during the weaving of the pillars and base.

During the weaving, the weft threads 29, 3|], 3| and 32 in the body extending from pillars to pillars are moved step by step by the take-up with weft threads in the position to which they were beaten by the lay, and, after beating weft 2|, the movement of the take-up is arrested. Weft thread 22 is then passed through the shed between warp threads 2, 4, 5, 6 and 8, above the shed and warp threads I, 3, I, 9, I0, II and I2 below the shed, and, when weft thread 22 is beaten up due to the fixed position of weft 2| and the light tension on warp threads 3 and I, warp threads 22 together with wefts 3 and 1 will be folded under weft thread 2 I.

Weft thread 23 is kept positioned in a shed below warp threads I, 3, 4, 5, 6 and I and above warp threads 2, 8, 9, I0, II and I2, and, when beaten up, will fold under weft 22.

Weft thread 24 is then positioned in a shed below warp threads I, 2, 3, 4, 5, 6, I, 8, 9, I0 and I2 and above warp thread II, and, when beaten up, will be folded under weft thread 23. Weft thread 25 is then positioned in a shed below warp threads I, 2, 3, 4, 5, 6, I, 8, 9 and II and above warp threads I0 and I2, and, when beaten up, will slip between warp threads I0, I I and I2 and will force warp thread 24 further under warp thread 23.

Weft thread 26 is then positioned in a shed below warp threads 2, 3', 4, 5, 6, 1, 8, I9 and I2 and above warp threads I, 9 and H and will be folded over weft 25 when beaten up.

Weft thread 21 is then positioned in a shed below warp threads I, 3, 4, 5, 6, 8 and 9 and above warp threads 2, I9, II and I2, and, when beaten up, will be folded over weft thread 26.

Weft thread 28 is then positioned in a shed below warp threads 2, 3, 4, 5, 6 and 8 and above warp threads I, I, 9, I 0, II and I2, and, when beaten up, will be folded over weft thread 21.

Weft thread 29 is then positioned in a shed below warp threads 3, 5 and I and above warp threads I, 2, 4, 6, 8, 9, I6, II and I2. The take-up is now released and weft 29 is beaten up to close any gap between weft threads 2| and 29, and, during such beating, will slip between warp threads 4, 5 and 6 due to the high tension always maintained on warp threads 4, 5 and 6 and the low surface friction of said warp and weft thread 29.

The weft threads 30, 3 I, 32 and 2| are then suc cessively positioned as above described.

In Figure 17, we have shown a sectional view similar to Figure 15 on the line I 5--I 5 of Figure 14 between warp 3 and 4 with the woolen warp threads forming the pile face of the fabric. At the right end of Figure 15, pile threads 50 have been shown interwoven with weft threads 3|, 32, 2|, 29 and 30 in the usual manner with the body warp threads 4, 5 and 6.

One of the advantages of our invention results from the provision of a pad which may be formed for use as a pad under a piece of fabric, a carpet or rug, in which the upper surface or body is substantially closed between the warp and weft threads in the upper layer which is provided with a base and a plurality of spaced supporting pillars between the base and the body of the pad.

Another advantage results from the provision of a combined carpet or other fabric and a pad in which the body of the fabric and the pad are formed of the same warp and weft threads, greatly reducing the cost where it is desired to provide a fabric or carpet with an underlying pad, thus not only reducing the amount of yarn used, but also the cost of weaving two separate fabrics instead of one.

Another advantage of our invention results from the provision of a carpet or fabric which is greatly strengthened by the interweaving of the honeycomb base of the pad and supporting pillar with the body of the carpet.

Another advantage results from the provision of a carpet with a pad interwoven therewith as the carpet and underlying pad are always maintained in proper relation to each other and thus prevents the carpet from slipping over the pad at one edge and exposing the pad at the opposite edge.

Another advantage results from the provision of a method of weaving whereby a fabric or carpet which is to be provided with an underlying pad may be simultaneously woven and, at the same time, the use of some of the warp and weft threads for forming the body of the carpet as well as the body or upper portion of the pad.

It will beevident that numerous variations in the invention may be made without departing from the principles thereof as defined in the following claims.

What we claim and desire to protect by Letters Patent is:

1. A woven pad comprising a body having a supporting surface for an overlying fabric, a base and a plurality of spaced body supporting pillars, the body having a plurality of spaced groups of warp threads interwoven with a plurality of weft threads in the same horizontal plane, the base being in a lower horizontal plane, having a plurality of spaced groups'of warp threads interwoven with a plurality of spaced groups of weft threads in substantially the same horizontal plane, the spaced pillars each having a plurality of weft threads in two vertical planes between the base and the body underlying a pair of weft threads in the body and overlying a group of weft threads in the base, some of the warp threads in the body and base being interwoven with the pillar weft threads, providing a honey comb effect in the base.

2. A woven pad in accordance with claim 1, characterized in that the warp threads in the base lie in vertical planes between vertical planes extending through the warp threads in the body portion.

3. A woven pad in accordance with claim 1 characterized in that the body forms the body for a pad underlying a woven fabric, the surface forming warp of the fabric being interwoven with the weft threads of the body of the pad, whereby a fabric and an underlying pad are woven integral with each other with an intermediate body for the pad and the fabric.

4. A combined Wilton carpet and an underlying pad therefor woven integrally therewith comprising a body woven of a plurality of warp threads and a plurality of weft threads, a base having a plurality of spaced groups of warp threads and a plurality of spaced groups of weft threads, a pillar between the body and the base at each junction between each group of weft threads and each group of warp threads in the base, said pillars being formed of two vertical rows of weft threads and warp threads, the upper weft threads in the pillars lying under adjacent weft threads in the body and interwoven therewith by warp threads in the body, the two weft threads in the pillars adjacent to the base being interwoven with the weft threads in the base and pile threads forming the face of the carpet interwoven with the weft threads in the body.

5. A carpet comprising a body having warp threads interwoven with weft threads, carpet facing warp threads interwoven with weft threads of the body, a base below the body being interwoven with spaced groups of warp and weft threads, two columns of pillar of weft threads above each group of weft threads in the base, the lower weft threads of each column being interwoven with the weft threads of the base by the warp threads in the base and a warp thread at each side of the warp threads in the base overlying the weft threads in the columns, the upper threads in the pillars being interwoven with adjacent weft threads in the body by the warp threads in the body and warp threads interwoven with the weft threads in the columns of the pillars floating from pillar to pillar, whereby the carpet is provided with an integral pad having a base of honeycomb weave.

6. A woven pad comprising a body of contiguous spans having a supporting surface for an overlying fabric, a base and a plurality of spaced body supporting pillars in spaced transverse rows between the body and base, the body having a plurality of spaced groups of five warp threads in each group and five weft threads interwoven therewith in each span extending from one row of pillars to the next, a base in a lower plane having a plurality of spaced groups of five warp threads in each group and spaced groups of three Weft threads in each group interlaced with each other which float between adjacent pillars, each of the spaced pillars having a plurality of weft threads in two vertical columns between the base and the body underlying a pair of adjacent weft threads in the body and overlying a group of weft threads in the base, some of the warp threads in the body being interwoven with the weft threads in the pillars, while the warp threads in the base are interwoven with the pillar weft threads.

7. A woven pad comprising a body, a base and a plurality of spaced base supporting pillars, the body having a closely woven fabric supporting surface, a plurality of contiguous spans extending from pillar to pillar, a plurality of spaced groups of warp threads, each group having five warp threads and five weft threads in each span interwoven with each other, a base in a lower plane having spaced groups of warp threads and spaced groups of three weft threads in each interlaced with the warp threads in the base,

spaced pillars each having a plurality of weft threads in two vertical columns between the base and the body underlying each weft thread at the end of an adjacent span in the body and overlying a group of weft threads in the base, the three intermediate warp threads in the body being interwoven only with each weft thread in the spans, while a weft thread at each side of the three intermediate weft threads in adjacent groups being interwoven with all of the weft threads in the body and the two weft threads underlying the said weft threads in the spans, while the weft threads of the pillars overlying the three weft threads in the base are interwoven with the three weft threads in the base and float from pillar to pillar, and a warp thread on each side of the three warp threads in the base from adjacent groups being interwoven with the weft threads in the base and those in the pillar overlying the base.

8. A woven pad comprising a body, a base, and a, plurality of spaced supporting pillars between the base and the body including four groups of warp threads A, B, C and D, the warp threads of group B being entirely in the plane of the body and interwoven with weft threads in the same plane to provide a closely woven upper surface on the body, group D of warp threads spaced transversely from group B being entirely in the plane of the base and interwoven with weft threads in substantially the same plane in the base of the pillars and floating from pillar to pillar, group C of warp threads bein on one side of group D of warp threads and group A of warp threads on the other side of the group C of warp threads, the weft threads in the pillars being in two vertical planes between the base and weft threads in the body, one of the warp threads of each of groups C and A adjacent to the warp threads in group B being interwoven with the weft threads in the body and the two upper Weft threads in the pillars below the adjacent weft threads in the body, one of the warp threads in each of groups C and A adjacent to the warp threads in group D being interwoven with the Weft threads in the base and the lower weft threads in the pillars immediately above the base, the other warp threads of groups C and A being interwoven with the weft threads in the pillars between the upper and lower weft threads in the pillars and floating from pillar to pillar.

9. A carpet interwoven with an underlying pad comprising a body, a base, and a plurality of spaced supporting pillars between the base and the body including four groups of warp threads A, B, C and D of three threads each and twelve weft threads, the body having contiguous spans, the ends of adjacent spans being supported on adjacent pillars, the warp threads of groups B being entirely in the plane of the body and interwoven with five weft threads in each span to provide a closely woven upper surface on the body, groups D of warp threads spaced from groups B being entirely in the plane of the base and interwoven with three weft threads in substantially the same plane, groups C of warp threads on one side of groups D and groups A on the other side of the groups D, the weft threads in the pillars being in two vertical planes of two each between adjacent weft threads in the spans of the body and the base, one of the warp woven with the adjacent weft threads in the spans and the two upper weft threads in the pillars below adjacent weft threads in the spans, one of the warp threads in each of groups C and A adjacent to the warp threads in groups D bein interwoven with the three Weft threads in the base and the lower weft threads in the pillars immediately above the base, the other warp threads of groups C and A being interwoven with the weft threads in the pillars, between the upper and lower weft threads in the pillars, the weft threads forming the surface of the carpet being interwoven with the weft threads in the body in the usual manner.

10. The method of weaving a pad having a body formed of contiguous spans in a horizontal plane woven of adjacent weft and warp threads to form a substantially closed upper surface, a base in a lower horizontal plane formed of spaced rows of adjacent weft and warp threads to form a honeycomb lower surface and spaced supporting pillars between the base and the body each formed of adjacent vertical rows of weft threads between the adjacent weft threads of the spans and the weft threads of the base interwoven with each other by warp threads between the body and base and weft threads in the spans and base interwoven with warp threads in the spans and base, supplying the warp threads from four spaced groups A, B, C and D during the weaving, weaving the spans from pillar to pillar with Weft threads pick by pick and with all of the warp threads in group B while applying a heavy tension to the warp threads in group B and with a warp thread from each of groups A and C while applying a low tension to the warp threads in groups A and C, beating up the successive picks and taking them up pick by pick for each pick in a span, except the last pick, in the next pick interweaving a weft thread with a warp thread from each of groups A and C, beating up the pick and as the warp threads from groups A and C are under low tension, said weft thread, together with the warp threads from groups A and C will be folded under the last pick of the span forming the first weft of the first vertical row pillar weft threads under the end of a span, in the next pick interweaving the lower weft thread in the first row of wefts in the pillars with warp threads from groups A and C which are folded under the first pillar weft thread thereabove, in the first pick of the base below the lower pillar weft thread, the first weft in the base is interwoven with all of the warp threads from group D under high tension and a warp thread from each of groups A and C beating up the weft and as warps from A and C under low tension in successive repeats of the pad.

HAROLD P. FARIS. BERNARD R. KOENIG.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Name Date Stewart Feb. 21, 1905 Stewart June 19, 1906 Brooks June 4, 1918 Barbet Apr. 16, 1935 Preneta July 29, 1947 Glendinning et a1. July 29, 1947 Number 

